Johnson Controls YORK YCAL0041EC Owner's manual

YCAL0041EC - YCAL0071EC
AIR-COOLED
SCROLL CHILLERS
STYLE D
WITH IPU II & I/O BOARDS
(60 Hz)
35-60 TON
INSTALLATION, OPERATION, MAINTENANCE
AIR-COOLED LIQUID CHILLERS
HERMETIC SCROLL
Supersedes 150.66-NM1 (1005) Form 150.66-NM1 (708)
LD10950
R-22
035-20895-000

JOHNSON CONTROLS
2
FORM 150.66-NM1 (708)
This equipment is a relatively complicated apparatus.
During installation, operation, maintenance or service,
individuals may be exposed to certain components or
conditions including, but not limited to: refrigerants,
oils, materials under pressure, rotating components,
and both high and low voltage. Each of these items
has the potential, if misused or handled improperly, to
cause bodily injury or death. It is the obligation and
responsibility of operating/service personnel to identify
and recognize these inherent hazards, protect themselves,
and proceed safely in completing their tasks. Failure to
comply with any of these requirements could result in
serious damage to the equipment and the property in
IMPORTANT!
READ BEFORE PROCEEDING!
GENERAL SAFETY GUIDELINES
which it is situated, as well as severe personal injury or
death to themselves and people at the site.
This document is intended for use by owner-authorized
operating/service personnel. It is expected that this
individual possesses independent training that will
enable them to perform their assigned tasks properly
and safely. It is essential that, prior to performing any
task on this equipment, this individual shall have read
and understood this document and any referenced
materials. This individual shall also be familiar with and
comply with all applicable governmental standards and
regulations pertaining to the task in question.
SAFETY SYMBOLS
The following symbols are used in this document to alert the reader to areas of potential hazard:
CAUTION identifies a hazard which
could lead to damage to the machine,
damage to other equipment and/or
environmental pollution. Usually an
instruction will be given, together with
a brief explanation.
NOTE is used to highlight additional
information which may be helpful to
you.
DANGER indicates an imminently
hazardous situation which, if not
avoided, will result in death or serious
injury.
WARNING indicates a potentially
hazardous situation which, if not
avoided, could result in death or se-
rious injury.
External wiring, unless specified as an optional connection in the manufacturer’s product
line, is NOT to be connected inside the micro panel cabinet. Devices such as relays, switches,
transducers and controls may NOT be installed inside the panel. NO external wiring is al-
lowed to be run through the micro panel. All wiring must be in accordance with YORK’s
published specifications and must be performed ONLY by qualified YORK personnel. YORK
will not be responsible for damages/problems resulting from improper connections to the
controls or application of improper control signals. Failure to follow this will void the
manufacturer’s warranty and cause serious damage to property or injury to persons.

FORM 150.66-NM1 (708)
3
JOHNSON CONTROLS
CHANGEABILITY OF THIS DOCUMENT
In complying with YORK’s policy for continuous product improvement, the information contained in this document
is subject to change without notice. While YORK makes no commitment to update or provide current information
automatically to the manual owner, that information, if applicable, can be obtained by contacting the nearest YORK
Engineered Systems Service office.
It is the responsibility of operating/service personnel to verify the applicability of these documents to the equipment in
question. If there is any question in the mind of operating/service personnel as to the applicability of these documents,
then prior to working on the equipment, they should verify with the owner whether the equipment has been modified
and if current literature is available.

JOHNSON CONTROLS
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FORM 150.66-NM1 (708)
TABLE OF CONTENTS
GENERAL SAFETY GUIDELINES......................................................................................................2
TABLE OF CONTENTS .......................................................................................................................4
LIST OF FIGURES...............................................................................................................................9
LIST OF TABLES...............................................................................................................................10
SECTION 1 - GENERAL CHILLER INFORMATION & SAFETY ......................................................13
INTRODUCTION .........................................................................................................................................13
WARRANTY ................................................................................................................................................13
SAFETY.......................................................................................................................................................13
Standards for Safety ...........................................................................................................................13
RESPONSIBILITY FOR SAFETY ...............................................................................................................14
ABOUT THIS MANUAL ..............................................................................................................................14
MISUSE OF EQUIPMENT...........................................................................................................................14
Suitability for Application ...................................................................................................................14
Structural Support...............................................................................................................................14
Mechanical Strength ..........................................................................................................................15
General Access....................................................................................................................................15
Pressure Systems ...............................................................................................................................15
Electrical...............................................................................................................................................15
Rotating Parts ......................................................................................................................................15
Sharp Edges.........................................................................................................................................15
Refrigerants and Oils ..........................................................................................................................15
High Temperature and Pressure Cleaning ........................................................................................15
Emergency Shutdown.........................................................................................................................15
SECTION 2 - PRODUCT DESCRIPTION..........................................................................................16
INTRODUCTION .........................................................................................................................................16
GENERAL SYSTEM DESCRIPTION ..........................................................................................................16
Compressors .......................................................................................................................................16
Cooler ...................................................................................................................................................16
Condenser............................................................................................................................................17
Millennium Control Center..................................................................................................................17
Power Panel .........................................................................................................................................18
ACCESSORIES AND OPTIONS .................................................................................................................19
Power Options: ....................................................................................................................................19
Control Options: ..................................................................................................................................19
Compressor, Piping, Evaporator Options .........................................................................................20
Condenser and Cabinet Options........................................................................................................20
Sound Reduction Options ..................................................................................................................21
UNIT COMPONENTS..................................................................................................................................22
CONTROL / POWER PANEL COMPONENTS ...........................................................................................23
PRODUCT IDENTIFICATION NUMBER (PIN)............................................................................................24
UNIT NOMENCLATURE .............................................................................................................................24
BASIC UNIT NOMENCLATURE .................................................................................................................24
REFRIGERANT FLOW DIAGRAM .............................................................................................................29
SECTION 3 - HANDLING AND STORAGE.......................................................................................30
DELIVERY AND STORAGE........................................................................................................................30
INSPECTION ...............................................................................................................................................30
MOVING THE CHILLER..............................................................................................................................30
Lifting Weights.....................................................................................................................................30
UNIT RIGGING ............................................................................................................................................31

FORM 150.66-NM1 (708)
5
JOHNSON CONTROLS
TABLE OF CONTENTS (CONT’D)
SECTION 4 - INSTALLATION ...........................................................................................................32
INSTALLATION CHECKLIST......................................................................................................................32
HANDLING ..................................................................................................................................................32
INSPECTION ...............................................................................................................................................32
LOCATION AND CLEARANCES................................................................................................................32
Foundation ...........................................................................................................................................33
Ground Level Locations .....................................................................................................................33
Rooftop Locations...............................................................................................................................33
Noise Sensitive Locations ..................................................................................................................33
SPRING ISOLATORS (OPTIONAL)............................................................................................................33
COMPRESSOR MOUNTING ......................................................................................................................33
REMOTE COOLER OPTION ......................................................................................................................33
CHILLED LIQUID PIPING ...........................................................................................................................33
DUCT WORK CONNECTION ....................................................................................................................34
WIRING........................................................................................................................................................34
Evaporator Pump Start Contacts .......................................................................................................35
System Run Contacts .........................................................................................................................35
Alarm Status Contacts ........................................................................................................................35
Remote Start/Stop Contacts...............................................................................................................35
Remote Emergency Cutoff .................................................................................................................35
PWM Input ............................................................................................................................................35
Load Limit Input...................................................................................................................................35
Flow Switch Input ................................................................................................................................35
COMPRESSOR HEATERS .........................................................................................................................35
SINGLE-POINT SUPPLY CONNECTION – TERMINAL BLOCK, NON-FUSED DISCONNECT
SWITCH OR CIRCUIT BREAKER (0041 - 0071) .......................................................................................36
SINGLE-POINT SUPPLY CONNECTION ...................................................................................................36
CONTROL WIRING.....................................................................................................................................37
SECTION 5 - COMMISSIONING .......................................................................................................38
PREPARATION – POWER OFF..................................................................................................................38
Inspection ...........................................................................................................................................38
Refrigerant Charge ..............................................................................................................................38
Service and Oil Line Valves ................................................................................................................38
Compressor Oil....................................................................................................................................38
Fans .....................................................................................................................................................38
Isolation / Protection ...........................................................................................................................38
Control Panel .......................................................................................................................................38
Power Connections .............................................................................................................................38
Grounding ............................................................................................................................................39
Supply Voltage.....................................................................................................................................39
PREPARATION – POWER ON ...................................................................................................................39
Switch Settings....................................................................................................................................39
Compressor Heaters ...........................................................................................................................39
Water System .......................................................................................................................................39
Flow Switch..........................................................................................................................................39
Temperature Sensor(s) .......................................................................................................................39
EQUIPMENT STARTUP CHECKLIST ........................................................................................................40
Checking the System Prior To Initial Start (No Power) ....................................................................40
Compressor Heaters (Power ON – 24 Hours Prior To Start) ...........................................................40
Panel Checks (Power ON – Both Unit Switches OFF)....................................................................40

JOHNSON CONTROLS
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FORM 150.66-NM1 (708)
TABLE OF CONTENTS (CONT’D)
SETPOINTS ENTRY LIST...........................................................................................................................41
CHECKING SUPERHEAT AND SUBCOOLING.........................................................................................42
LEAK CHECKING .......................................................................................................................................42
UNIT OPERATING SEQUENCE .................................................................................................................43
SECTION 6 - TECHNICAL DATA ......................................................................................................44
OPERATIONAL LIMITATIONS (ENGLISH) ................................................................................................44
Temperatures and Flows ....................................................................................................................44
Voltage Limitations..............................................................................................................................44
Ethylene Glycol Correction Factors ..................................................................................................45
OPERATIONAL LIMITATIONS (SI).............................................................................................................46
Temperatures and Flows ....................................................................................................................46
Voltage Limitations..............................................................................................................................46
Ethylene Glycol Correction Factors ..................................................................................................47
PHYSICAL DATA (ENGLISH) .....................................................................................................................48
SOUND DATA (ENGLISH) ..........................................................................................................................50
ELCTRICAL DATA (ENGLISH) ...................................................................................................................52
ELECTRICAL NOTES AND LEGEND ........................................................................................................55
WIRING DIAGRAMS ...................................................................................................................................56
CONNECTION DIAGRAMS ........................................................................................................................63
DIMENSIONS - (ENGLISH).........................................................................................................................66
DIMENSIONS - (SI) .....................................................................................................................................80
TECHNICAL DATA - CLEARANCES..........................................................................................................94
ISOLATORS ................................................................................................................................................95
SECTION 7 - UNIT CONTROLS......................................................................................................101
INTRODUCTION .......................................................................................................................................101
MICROPROCESSOR BOARD..................................................................................................................101
UNIT SWITCH ...........................................................................................................................................102
DISPLAY....................................................................................................................................................102
KEYPAD ....................................................................................................................................................102
BATTERY BACK-UP.................................................................................................................................102
TRANSFORMER ......................................................................................................................................102
SINGLE SYSTEM SELECT ANDPROGRAMMING # OF COMPRESSORS ..........................................102
“STATUS” KEY ........................................................................................................................................103
Unit Status..........................................................................................................................................103
General Status Messages .................................................................................................................103
Fault safety Status Messages ..........................................................................................................105
System Safeties............................................................................................................................105
Unit Safeties: ................................................................................................................................107
Unit Warning ......................................................................................................................................107
STATUS KEY MESSAGES QUICK REFERENCE LIST...........................................................................108
DISPLAY/PRINT KEYS .............................................................................................................................109
Oper Data Key....................................................................................................................................109
Operation Data Quick Reference List .............................................................................................. 112
Print Key.............................................................................................................................................113
Operating Data Printout ....................................................................................................................113
History Printout .................................................................................................................................114
History Displays ................................................................................................................................114
Software Version ...............................................................................................................................116

FORM 150.66-NM1 (708)
7
JOHNSON CONTROLS
TABLE OF CONTENTS (CONT’D)
“ENTRY” KEYS......................................................................................................................................... 117
Up and Down Arrow Keys.................................................................................................................117
Enter/Adv Key ....................................................................................................................................117
“SETPOINTS” KEYS ................................................................................................................................118
Cooling Setpoints..............................................................................................................................118
Leaving Chilled Liquid Control ........................................................................................................118
Return Chilled Liquid Control ..........................................................................................................119
Remote Setpoint Control ..................................................................................................................119
Schedule/advance Day Key ..............................................................................................................119
Program Key ......................................................................................................................................121
System Trip Volts .........................................................................................................................122
Unit Trip Volts ...............................................................................................................................123
Program Key Limits and Defaults ....................................................................................................124
Setpoints Quick Reference List .......................................................................................................125
“UNIT” KEYS ...........................................................................................................................................126
Options Key .......................................................................................................................................126
CLOCK ......................................................................................................................................................130
UNIT KEYS PROGRAMMING QUICK REFERENCE LIST ......................................................................131
SECTION 8 - UNIT OPERATION.....................................................................................................132
CAPACITY CONTROL ..............................................................................................................................132
SUCTION PRESSURE LIMIT CONTROLS ..............................................................................................132
DISCHARGE PRESSURE LIMIT CONTROLS .........................................................................................132
LEAVING CHILLED LIQUID CONTROL...................................................................................................132
LEAVING CHILLED LIQUID CONTROLOVERRIDE TO REDUCE CYCLING.........................................133
LEAVING CHILLED LIQUID SYSTEM LEAD/LAG AND COMPRESSOR SEQUENCING .....................133
RETURN CHILLED LIQUID CONTROL....................................................................................................133
RETURN CHILLLED LIQUID SYSTEM LEAD/LAG AND COMPRESSOR SEQUENCING ....................134
ANTI-RECYCLE TIMER ............................................................................................................................135
ANTI-COINCIDENCE TIMER ....................................................................................................................135
EVAPORATOR PUMP CONTROL ............................................................................................................135
EVAPORATOR HEATER CONTROL........................................................................................................135
PUMPDOWN CONTROL ..........................................................................................................................136
CONDENSER FAN CONTROL .................................................................................................................136
LOW AMBIENT FAN CONTROL OPTION................................................................................................138
General ...............................................................................................................................................138
Configuration (Jumpers and Potentiometers) ................................................................................139
Wiring .................................................................................................................................................140
PROGRAMMING.......................................................................................................................................141
LOAD LIMITING ........................................................................................................................................141
COMPRESSOR RUN STATUS .................................................................................................................142
ALARM STATUS .......................................................................................................................................142
EMS-PWM REMOTE TEMPERATURE RESET........................................................................................142
BAS/EMS TEMPERATURE RESET OPTION...........................................................................................143

JOHNSON CONTROLS
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FORM 150.66-NM1 (708)
TABLE OF CONTENTS (CONT’D)
SECTION 9 - SERVICE AND TROUBLESHOOTING .....................................................................145
CLEARING HISTORY BUFFERS .............................................................................................................145
SERVICE MODE – OUTPUTS ..................................................................................................................145
SERVICE MODE – CHILLER CONFIGURATION.....................................................................................145
SERVICE MODE – INPUTS ......................................................................................................................146
CONTROL INPUTS/OUTPUTS.................................................................................................................147
IPU II & I/O LAYOUT .................................................................................................................................148
CHECKING INPUTS AND OUTPUTS.......................................................................................................149
Digital Inputs......................................................................................................................................149
Analog Inputs – Temperature ...........................................................................................................149
Outside Air Sensor ............................................................................................................................149
Liquid & Refrigerant Sensor Test Points ........................................................................................150
Analog Inputs – Pressure .................................................................................................................151
Digital Outputs...................................................................................................................................152
OPTIONAL PRINTER INSTALLATION.....................................................................................................153
Parts....................................................................................................................................................153
Assembly and Wiring ........................................................................................................................153
Obtaining a Printout ..........................................................................................................................153
TROUBLESHOOTING ..............................................................................................................................154
SECTION 10 - MAINTENANCE.......................................................................................................157
IMPORTANT ..............................................................................................................................................157
COMPRESSORS.......................................................................................................................................157
Oil Level check ..................................................................................................................................157
Oil Analysis ........................................................................................................................................157
CONDENSER FAN MOTORS ...................................................................................................................157
CONDENSER COILS ................................................................................................................................157
OPERATING PARAMETERS ....................................................................................................................157
ON-BOARD BATTERY BACK-UP ............................................................................................................157
PLATE AND FRAME HEAT EXCHANGER (EVAPORATOR) HEATER...................................................157
OVERALL UNIT INSPECTION .................................................................................................................158
ISN CONTROL ..........................................................................................................................................159
Received Data (Control Data) ...........................................................................................................159
Transmitted Data ...............................................................................................................................159
BACNET AND MODBUS DATA COMMUNICATION................................................................................162

FORM 150.66-NM1 (708)
9
JOHNSON CONTROLS
LIST OF FIGURES
FIG. 1 – REFRIGERANT FLOW DIAGRAM......................................................................................29
FIG. 2 – SINGLE-POINT SUPPLY CONNECTION – TERMINAL BLOCK, NON-FUSED
DISCONNECT SWITCH OR CIRCUIT BREAKER (0041 - 0071) .......................................36
FIG. 3 – CONTROL WIRING ............................................................................................................37
FIG. 4 – CONTROL CIRCUIT, DUAL.................................................................................................56
FIG. 5 – CONTROL CIRCUIT, DUAL.................................................................................................58
FIG. 6 – POWER CIRCUIT, DUAL.....................................................................................................60
FIG. 7 – POWER CIRCUIT, DUAL.....................................................................................................61
FIG. 8 – WIRING DETAILS ................................................................................................................62
FIG. 9 – CONNECTION DIAGRAM ...................................................................................................63
FIG. 10 – CONNECTION DIAGRAM .................................................................................................64
FIG. 11 – CONNECTION DIAGRAM MICROBOARD (PARTIAL) ....................................................65
FIG. 12 – UNIT CLEARANCES .........................................................................................................94
FIG. 13 – LEAVING WATER TEMPERATURE CONTROL EXAMPLE...........................................133
FIG. 14 – SETPOINT ADJUST ........................................................................................................133
FIG. 15 – YCAL0041 – YCAL0071 FAN LOCATION (TYPICAL) ...................................................137
FIG. 16 – TYPICAL INVERTER LOCATION ...................................................................................138
FIG. 17 – INVERTER ENCLOSURE................................................................................................138
FIG. 18 – POTENTIOMETER SETTINGS........................................................................................139
FIG. 19 – INVERTER POWER WIRING SCHEMATIC ....................................................................140
FIG. 20 – INVERTER WIRING.........................................................................................................140
FIG. 21 – FIELD AND FACTORY ELECTRICAL CONNECTIONS OPTIONAL REMOTE
TEMPERATURE RESET BOARD ...................................................................................144
FIG. 22 – IPU II & I/O LAYOUT........................................................................................................148
FIG. 23 – MICROBOARD RELAY CONTACT ARCHITECTURE....................................................152
FIG. 24 – PRINTER TO MICROBOARD ELECTRICAL CONNECTIONS ......................................153

JOHNSON CONTROLS
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FORM 150.66-NM1 (708)
LIST OF TABLES
TABLE 1 – SETPOINTS ENTRY LIST...............................................................................................41
TABLE 2 – TEMPERATURES AND FLOWS.....................................................................................44
TABLE 3 – VOLTAGE LIMITATIONS ................................................................................................44
TABLE 4 – ETHYLENE GLYCOL CORRECTION FACTORS ..............................................................45
TABLE 5 – TEMPERATURES AND FLOWS (SI)..............................................................................46
TABLE 6 – VOLTAGE LIMITATIONS ................................................................................................46
TABLE 7 – ETHYLENE GLYCOL CORRECTION FACTORS ..............................................................47
TABLE 8 – PHYSICAL DATA (ENGLISH) .........................................................................................48
TABLE 9 – SOUND DATA (ENGLISH) ..............................................................................................50
TABLE 10 – ELECTRICAL DATA (ENGLISH) ..................................................................................52
TABLE 11 – MICRO PANEL POWER SUPPLY ................................................................................54
TABLE 12 – VOLTAGE RANGE ........................................................................................................54
TABLE 13 – STATUS KEY MESSAGES QUICK REFERENCE LIST.............................................108
TABLE 14 – OPERATION DATA .....................................................................................................112
TABLE 15 – COOLING SETPOINTS, PROGRAMMABLE LIMITS AND DEFAULTS....................120
TABLE 16 – PROGRAM KEY LIMITS AND DEFAULTS ................................................................124
TABLE 17 – SETPOINTS QUICK REFERENCE LIST....................................................................125
TABLE 18 – UNIT KEYS PROGRAMMING QUICK REFERENCE LIST........................................131
TABLE 19 – COMPRESSOR STAGING FOR RETURN WATER CONTROL.................................134
TABLE 20 – RETURN CHILLED LIQUID CONTROL FOR 4 COMPRESSORS (6 STEPS) ..........135
TABLE 21 – RETURN CHILLED LIQUID CONTROL FOR 4 COMPRESSORS (6 STEPS) ..........136
TABLE 22 – YCAL0041 – YCAL0071 CONDENSER FAN CONTROL USING OUTDOOR
AMBIENT TEMPERATURE AND DISCHARGE PRESSURE (DISCHARGE
PRESSURE CONTROLS WILL NOT FUNCTION AND FAN CONTROL WILL BE
BASED ON AMBIENT TEMPERATURES ONLY, UNLESS THE OPTIONAL
DISCHARGE PRESSURE .........................................................................................137
TABLE 23 – YCAL0041 – YCAL0071 CONDENSER FAN CONTROL USING DISCHARGE
PRESSURE ONLY ......................................................................................................137
TABLE 24 – INVERTER OPTION CONDENSER FAN CONTROL OPERATION...........................141
TABLE 25 – COMPRESSOR OPERATION – LOAD LIMITING......................................................142
TABLE 26 – MICROBOARD DIGITAL INPUTS ..............................................................................147
TABLE 27 – MICROBOARD DIGITAL OUTPUTS ..........................................................................147
TABLE 28 – MICROBOARD ANALOG INPUTS .............................................................................147
TABLE 29 – MICROBOARD ANALOG OUTPUTS .........................................................................147
TABLE 30 – OUTDOOR AIR SENSOR TEMPERATURE/VOLTAGE/ RESISTANCE
CORRELATION ..........................................................................................................149
TABLE 31 – ENTERING/LEAVING CHILLED LIQUID TEMP. SENSOR, COOLER INLET
TEMPERATURE SENSOR, AND SUCTION TEMPERATURE SENSOR:
TEMPERATURE/VOLTAGE CORRELATION ............................................................150
TABLE 32 – TROUBLESHOOTING ................................................................................................154

FORM 150.66-NM1 (708)
11
JOHNSON CONTROLS
LIST OF TABLES (CONT’D)
TABLE 33 – ISN RECEIVED DATA .................................................................................................159
TABLE 34 – ISN TRANSMITTED DATA..........................................................................................159
TABLE 35 – ISN OPERATIONAL AND FAULT CODES .................................................................161
TABLE 36 – MINIMUM, MAXIMUM AND DEFAULT VALUES........................................................163
TABLE 37 – REAL TIME ERROR NUMBERS ................................................................................163

JOHNSON CONTROLS
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FORM 150.66-NM1 (708)
THIS PAGE INTENTIONALLY LEFT BLANK

FORM 150.66-NM1 (708)
13
JOHNSON CONTROLS
SECTION 1 - GENERAL CHILLER INFORMATION & SAFETY
INTRODUCTION
YORK YCAL0041-0071 chillers are manufactured
to the highest design and construction standards to
ensure high performance, reliability and adaptability
to all types of air conditioning installations.
The unit is intended for cooling water or glycol
solutions and is not suitable for purposes other than
those specified in this manual.
This manual contains all the information required for
correct installation and commissioning of the unit,
together with operating and maintenance instructions.
The manuals should be read thoroughly before
attempting to operate or service the unit.
All procedures detailed in the manuals, including
installation, commissioning and maintenance tasks
must only be performed by suitably trained and
qualified personnel.
The manufacturer will not be liable for any
injury or damage caused by incorrect installation,
commissioning, operation or maintenance resulting
from a failure to follow the procedures and
instructions detailed in the manuals.
WARRANTY
YORK International warrants all equipment and
materials against defects in workmanship and
materials for a period of eighteen months from date of
shipment, unless labor or extended warranty has been
purchased as part of the contract.
The warranty is limited to parts only replacement and
shipping of any faulty part, or sub-assembly, which
has failed due to poor quality or manufacturing errors.
All claims must be supported by evidence that the
failure has occurred within the warranty period, and
that the unit has been operated within the designed
parameters specified.
All warranty claims must specify the unit model,
serial number, order number and run hours/starts.
Model and serial number information is printed on the
unit identification plate.
The unit warranty will be void if any modification to
the unit is carried out without prior written approval
from YORK International.
For warranty purposes, the following conditions must
be satisfied:
• The initial start of the unit must be carried out
by trained personnel from an Authorized YORK
Service Center (see Commissioning Page 38).
• Only genuine YORK approved spare parts, oils,
coolants, and refrigerants must be used.
• All the scheduled maintenance operations detailed
in this manual must be performed at the specified
times by suitably trained and qualified personnel
(see Maintenance Section, Page 157).
• Failure to satisfy any of these conditions will
automatically void the warranty (see Warranty
Policy).
SAFETY
Standards for Safety
YCAL chillers are designed and built within an ISO
9002 accredited design and manufacturing organization.
The chillers comply with the applicable sections of the
following Standards and Codes:
• ANSI/ASHRAE Standard 15- Safety Code for
Mechanical Refrigeration.
• ANSI/NFPA Standard 70- National Electrical
Code (N.E.C.).
• ASME Boiler and Pressure Vessel Code- Section
VIII Division 1.
• ARI Standard 550/590-98- Water Chilling
Packages Using the Vapor Compression Cycle.
• ASHRAE 90.1- Energy Efficiency compliance.
• ARI 370- Sound Rating of Large Outdoor
Refrigeration and Air Conditioning Equipment.
In addition, the chillers conform to Underwriters
Laboratories (U.L.) for construction of chillers and
provide U.L./cU.L. Listing Label.

JOHNSON CONTROLS
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FORM 150.66-NM1 (708)
General Chiller Introduction & Safety
RESPONSIBILITY FOR SAFETY
Every care has been taken in the design and
manufacture of the unit to ensure compliance with
the safety requirements listed above. However, the
individual operating or working on any machinery is
primarily responsible for:
• Personal safety, safety of other personnel, and
the machinery.
• Correct utilization of the machinery in
accordance with the procedures detailed in the
manuals.
ABOUT THIS MANUAL
The following terms are used in this document to alert
the reader to areas of potential hazard.
A WARNING is given in this document to identify a
hazard, which could lead to personal injury. Usually
an instruction will be given, together with a brief
explanation and the possible result of ignoring the
instruction.
A CAUTION identifies a hazard which could lead to
damage to the machine, damage to other equipment
and/or environmental pollution. Usually an instruction
will be given, together with a brief explanation and
the possible result of ignoring the instruction.
A NOTE is used to highlight additional information,
which may be helpful to you but where there are no
special safety implications.
The contents of this manual include suggested best
working practices and procedures. These are issued
for guidance only, and they do not take precedence
over the above stated individual responsibility and/or
local safety regulations.
This manual and any other document supplied with
the unit are the property of YORK which reserves
all rights. They may not be reproduced, in whole or
in part, without prior written authorization from an
authorized YORK representative.
MISUSE OF EQUIPMENT
Suitability for Application
The unit is intended for cooling water or glycol
solutions and is not suitable for purposes other than
those specified in these instructions. Any use of the
equipment other than its intended use, or operation
of the equipment contrary to the relevant procedures
may result in injury to the operator, or damage to the
equipment.
The unit must not be operated outside the design
parameters specified in this manual.
Structural Support
Structural support of the unit must be provided as
indicated in these instructions. Failure to provide
proper support may result in injury to the operator, or
damage to the equipment and/or building.

FORM 150.66-NM1 (708)
15
JOHNSON CONTROLS
1
Mechanical Strength
The unit is not designed to withstand loads or stresses
from adjacent equipment, pipework or structures.
Additional components must not be mounted on the
unit. Any such extraneous loads may cause structural
failure and may result in injury to the operator, or
damage to the equipment.
General Access
There are a number of areas and features, which
may be a hazard and potentially cause injury when
working on the unit unless suitable safety precautions
are taken. It is important to ensure access to the unit
is restricted to suitably qualified persons who are
familiar with the potential hazards and precautions
necessary for safe operation and maintenance of
equipment containing high temperatures, pressures
and voltages.
Pressure Systems
The unit contains refrigerant vapor and liquid under
pressure, release of which can be a danger and cause
injury. The user should ensure that care is taken
during installation, operation and maintenance to
avoid damage to the pressure system. No attempt
should be made to gain access to the component parts
of the pressure system other than by suitably trained
and qualified personnel.
Electrical
The unit must be grounded. No installation or
maintenance work should be attempted on the
electrical equipment without first switching power
OFF, isolating and locking-off the power supply.
Servicing and maintenance on live equipment must
only be performed by suitably trained and qualified
personnel. No attempt should be made to gain access
to the control panel or electrical enclosures during
normal operation of the unit.
Rotating Parts
Fan guards must be fitted at all times and not
removed unless the power supply has been isolated. If
ductwork is to be fitted, requiring the wire fan guards
to be removed, alternative safety measures must be
taken to protect against the risk of injury from rotating
fans.
Sharp Edges
The fins on the air-cooled condenser coils have sharp
metal edges. Reasonable care should be taken when
working in contact with the coils to avoid the risk of
minor abrasions and lacerations. The use of gloves is
recommended.
Frame rails, brakes, and other components may also
have sharp edges. Reasonable care should be taken
when working in contact with any components to
avoid risk of minor abrasions and lacerations.
Refrigerants and Oils
Refrigerants and oils used in the unit are generally
nontoxic, non-flammable and non-corrosive, and pose
no special safety hazards. Use of gloves and safety
glasses is, however, recommended when working on
the unit. The build up of refrigerant vapor, from a
leak for example, does pose a risk of asphyxiation in
confined or enclosed spaces and attention should be
given to good ventilation.
High Temperature and Pressure Cleaning
High temperature and pressure cleaning methods
(e.g. steam cleaning) should not be used on any part
of the pressure system as this may cause operation of
the pressure relief device(s). Detergents and solvents,
which may cause corrosion, should also be avoided.
Emergency Shutdown
In case of emergency, the control panel is fitted
with a Unit Switch to stop the unit in an emergency.
When operated, it removes the low voltage 120
VAC electrical supply from the inverter system, thus
shutting down the unit.

JOHNSON CONTROLS
16
FORM 150.66-NM1 (708)
Product Description
SECTION 2 - PRODUCT DESCRIPTION
INTRODUCTION
YORK Millennium®Air-Cooled Scroll Chillers provide
chilled water for all air conditioning applications using
central station air handling or terminal units. They are
completely self-contained and are designed for outdoor
(roof or ground level) installation. Each unit includes
hermetic scroll compressors, a liquid cooler, air cooled
condenser, and a weather resistant microprocessor
control center, all mounted on a pressed steel base.
The units are completely assembled with all
interconnecting refrigerant piping and internal wiring,
ready for field installation.
Prior to delivery, the unit is pressure-tested,
evacuated, and fully charged with Refrigerant-22
(HCFC-22) and includes an initial oil charge. After
assembly, a complete operational test is performed
with water flowing through the cooler to assure that
the refrigeration circuit operates correctly.
The unit structure is heavy-gauge, galvanized steel. This
galvanized steel is coated with baked-on powder paint,
which, when subjected to ASTM B117 1000 hour, salt
spray testing, yields a minimum ASTM 1654 rating of
“6”. Corrosion resistant wire mesh panels are added to
protect the condenser coil from incidental damage and
restrict unauthorized access to internal components.
Units are designed in accordance with NFPA 70
(National Electric Code), ASHRAE/ANSI 15 Safety
code for mechanical refrigeration, ASME, Listed and
labeled with Intertek Testing Services (ETL) and rated
in accordance with ARI Standard 550/590-2003.
All exposed power wiring is routed through liquid-
tight, non-metallic conduit.
GENERAL SYSTEM DESCRIPTION
Compressors
The chiller has suction-gas cooled, hermetic, scroll
compressors. The YCAL compressors incorporate
a compliant scroll design in both the axial and
radial direction. All rotating parts are statically and
dynamically balanced. A large internal volume and oil
reservoir provides greater liquid tolerance. Compressor
crankcase heaters are also included for extra protection
against liquid migration.
Cooler
The Brazed Plate Heat Exchanger is equipped with a
heater controlled by the microprocessor. The heater
provides freeze protection for the cooler down to -20°F (-
29°C) ambient. The cooler is covered with 3/4” (19mm)
flexible, closed-cell, foam insulation (K~0.25).
LD10950

FORM 150.66-NM1 (708)
17
JOHNSON CONTROLS
2
Brazed plate heat exchangers shall be UL (Underwriters
Laboratories) listed. Installing contractor must include
accommodations in the chilled water piping to allow
proper drainage and venting of the heat exchanger. Water
inlet and outlet connections are grooved for compatibility
with factory supplied victaulic connections.
A strainer with a mesh size between .5 and 1.5 mm (40
mesh) is recommended upstream of the heat exchanger
to prevent clogging.
Condenser
Coils – Fin and tube condenser coils of seamless,
internally-enhanced, high-condensing-coefficient,
corrosion resistant copper tubes are arranged in
staggered rows, mechanically expanded into aluminum
fins. Integral subcooling is included. The design working
pressure of the coil is 450 PSIG (31 bar).
Low Sound Fans – The condenser fans are composed
of corrosion resistant aluminum hub and glass-fiber
reinforced composite blades molded into a low noise
airfoil section. They are designed for maximum
efficiency and are statically and dynamically balanced
for vibration free operation. They are directly driven
by independent motors, and positioned for vertical air
discharge. All blades are statically and dynamically
balanced for vibration-free operation. The fan guards
are constructed of heavy-gauge, rust-resistant, PVC
coated steel wire.
Motors – The fan motors are Totally Enclosed Air-
Over, squirrel-cage type, current protected. They feature
ball bearings that are double-sealed and permanently
lubricated.
Millennium Control Center
All controls are contained in a NEMA 3R/12 (and
equivalent to IP55*) cabinet with hinged outer door
and includes:
Liquid Crystal Display with Light Emitting Diode back-
lighting for outdoor viewing:
• Two display lines
• Twenty characters per line
Color coded 12-button non-tactile keypad with sections
for:
DISPLAY/PRINT of typical information:
•Chilled liquid temperatures
• Ambient temperature
• System pressures (each circuit)
• Operating hours and starts (each compressor)
• Print calls up to the liquid crystal display
• Operating data for the systems
• History of fault shutdown data for up to
the last six fault shutdown conditions.
• An RS-232 port, in conjunction with this
press-to-print button, is provided to permit
the capability of hard copy print-outs via a
separate printer (by others).
ENTRY section to:
ENTER setpoints or modify system values.
SETPOINTS updating can be performed to:
• Chilled liquid temperature setpoint and range
• Remote reset temperature range
• Set daily schedule/holiday for start/stop
• Manual override for servicing
• Low and high ambient cutouts
• Number of compressors
• Low liquid temperature cutout
• Low suction pressure cutout
• High discharge pressure cutout
• Anti-recycle timer (compressor start cycle
time)
• Anti-coincident timer (delay compressor
starts)
UNIT section to:
• Set time
• Set unit options
UNIT ON/OFF switch
The microprocessor control center is capable of
displaying the following:
• Return and leaving liquid temperature
• Low leaving liquid temperature cutout setting
• Low ambient temperature cutout setting
• Outdoor air temperature
• English or Metric data
• Suction pressure cutout setting
• Each system suction pressure

JOHNSON CONTROLS
18
FORM 150.66-NM1 (708)
Product Description
• Discharge pressure (optional)
• Liquid Temperature Reset via a YORK ISN DDC
or Building Automation System (by others) via:
- a pulse width modulated (PWM) input as stan-
dard.
- a 4-20 milliamp or 0 -10 VDC input, or contact
closure with the optional B.A.S. interface op-
tion.
• Anti-recycle timer status for each system
• Anti-coincident system start timer condition
• Compressor run status
• No cooling load condition
• Day, date and time
• Daily start/stop times
• Holiday status
• Automatic or manual system lead/lag control
• Lead system definition
• Compressor starts & operating hours
(each compressor)
• Status of hot gas valves, evaporator heater
and fan operation
• Run permissive status
• Number of compressors running
• Liquid solenoid valve status
• Load & unload timer status
• Water pump status
Provisions are included for: pumpdown at shutdown;
optional remote chilled water temperature reset and
two steps of demand load limiting from an external
building automation system. Unit alarm contacts are
standard.
The operating program is stored in non-volatile
memory (EPROM) to eliminate chiller failure due to
AC powered failure/battery discharge. Programmed
setpoints are retained in lithium battery-backed RTC
memory for 5 years minimum.
* Intensity of Protection European Standard
** International Electrotechnical Commission
Power Panel
Each panel contains:
• Compressor power terminals
• Compressor motor starting contactors per
l.E.C.**
• Control power terminals to accept incoming for
115-1-60 control power
• Fan contactors & overload current protection
The power wiring is routed through liquid-tight
conduit to the compressors and fans.

FORM 150.66-NM1 (708)
19
JOHNSON CONTROLS
2
ACCESSORIES AND OPTIONS
POWER OPTIONS:
COMPRESSOR POWER CONNECTION – Single-
point (YCAL0041-0071) terminal block connection is
provided as standard. The following power connections
are available as options. (See electrical data for specific
voltage and options availability) (Factory-Mounted).
SINGLE-POINT SUPPLY TERMINAL BLOCK
–(standard on YCAL0041 - 0071 models) Includes
enclosure, terminal-block and interconnecting wiring to
the compressors. Separate external protection must be
supplied, by others, in the incoming compressor-power
wiring. (Do not include this option if either the Single
Point Non Fused Disconnect Switch or Single-Point
Circuit Breaker options have been included).
SINGLE-POINT NON-FUSED DISCONNECT
SWITCH – Unit-mounted disconnect switch with
external, lockable handle (in compliance with Article
440-14 of N.E.C.), can be supplied to isolate the unit
power voltage for servicing. Separate external fusing
must be supplied, by others in the power wiring, which
must comply with the National Electrical Code and/or
local codes.
SINGLE-POINT CIRCUIT BREAKER – A unit
mounted circuit breaker with external, lockable handle
(in compliance with N.E.C. Article 440-14), can be
supplied to isolate the power voltage for servicing (this
option includes the Single-Point Power connection).
CONTROLTRANSFORMER – Converts unit power
voltage to 115-1-60 (0.5 or 1.0 KVA capacity). Fac-
tory mounting includes primary and secondary wiring
between the transformer and the control panel (Fac-
tory-Mounted).
POWER FACTOR CORRECTION CAPACITORS
–Will correct unit compressor power factors to a 0.90-
0.95 (Factory-Mounted).
CONTROL OPTIONS:
AMBIENT KIT (LOW) – Units will operate to 25°F (-
4°C). This accessory includes all necessary components
to permit chiller operation to 0°F (-18°C). (This option
includes the Discharge Pressure Transducer / Readout
Capability option). For proper head pressure control
in applications below 25°F (-4°C), where wind gusts
may exceed five mph, it is recommended that Optional
Condenser Louvered Enclosure Panels also be included
(Factory-Mounted).
AMBIENT KIT (HIGH) – Required if units are to
operate when the ambient temperature is above 115°F
(46°C). Includes discharge pressure transducers. (This
option includes the Discharge Pressure Transducer /
Readout Capability option) (Field-Mounted).
BUILDING AUTOMATION SYSTEM INTER-
FACE – The factory addition of a Printed Circuit Board
to accept a 4-20 milliamp, 0-10VDC or contact closure
input to reset the leaving chiller liquid temperature from
a Building Automation System. (Only one of following
options can be offered on a unit at a time: BAS, Remote
Control Panel or Multi-unit Sequence Control) (Fac-
tory-Mounted). (The standard unit capabilities include
remote start/stop, remote water temperature reset via a
PWM input signal or up to two steps of demand (load)
limiting depending on model). (The standard control
panel can be directly connected to a YORK Building
Automated System via the standard onboard RS485
communication port).
LANGUAGE LCD AND KEYPAD DISPLAY – Span-
ish, French, and German unit LCD controls and keypad
displays are available. Standard language is English.
DISCHARGE PRESSURE TRANSDUCERS AND
READOUT CAPABILITY – The addition of pressure
transducers allows models to sense and display discharge
pressure. This is recommended for brine chilling appli-
cations. (This option is included with either the low or
high ambient kits) (Factory-Mounted).
• Suction Pressure Transducers: Permits unit to
sense and display suction pressure. This capability
is standard on YCAL0041-0071 models.
MOTOR CURRENT MODULE – Capable of moni-
toring compressor motor current. Provides extra protec-
tion against compressor reverse rotation, phase-loss and
phase imbalance. Option consists of one module per
electrical system (Factory-Mounted).
OPTIVIEW REMOTE CONTROL PANEL - Graphi-
cal interface panel to remotely control and monitor up to
8 different units. (Refer to form 201.18-SG4 for detailed
information).
MULTI-UNIT SEQUENCING – A separate Sequenc-
ing Control Center is provided to handle sequencing
control of up to eight chillers in parallel based on mixed
liquid temperature (interconnecting wiring by others).
(Only one of following options can be offered on a unit
at a time: BAS, Remote Control Panel or Multi-unit
Sequence Control) (Factory-Mounted).

JOHNSON CONTROLS
20
FORM 150.66-NM1 (708)
Product Description
COMPRESSOR, PIPING, EVAPORATOR OPTIONS
LOW TEMPERATURE BRINE – Required for brine
chilling below 30°F (-1°C) leaving brine temperature
for YCAL0041 - 0071 models. Option includes resized
thermal expansion valve (Factory-Mounted).
CHICAGO CODE RELIEF VALVES – Unit will
be provided with relief valves to meet Chicago code
requirements (Factory-Mounted).
SERVICE ISOLATION VALVE – Service suction
and discharge (ball type) isolation valves are added to
unit per system. This option also includes a system high
pressure relief valve in compliance with ASHRAE 15
(Factory-Mounted).
HOT GAS BY-PASS – Permits continuous, stable
operation at capacities below the minimum step of com-
pressor unloading to as low as 5% capacity (depending
on both the unit and operating conditions) by introduc-
ing an artificial load on the cooler. Hot gas by-pass is
installed on only refrigerant system #1 on two-circuited
units (Factory-Mounted).
DX COOLER 300 PSIG (21 bar) DWPWATERSIDE
– The waterside will be of 300 PSIG (21 bar) instead of
the standard 150 PSIG DWP. 300 PSIG R.F. flanges are
included on the DX cooler nozzles (Factory-Mounted).
The companion flanges will be field-supplied by oth-
ers.
FLANGES (VICTAULIC TYPE) – Consists of two
(2) Flange adapters for grooved end pipe (standard 150
psi [10.5 bar] cooler).
FLOW SWITCH – The flow switch or its equivalent
must be furnished with each unit.
150 PSIG (10.5 bar) DWP – For standard units. Johnson
Controls model F61MG-1C Vapor-proof SPDT, NEMA
4X switch (150 PSIG [10.5 bar] DWP), -20°F to 250°F
(-29°C to 121°C), with 1” NPT connection for upright
mounting in horizontal pipe (Field-Mounted).
300 psig (21 bar) DWP – For units with optional 300
PSIG (21 bar) DX cooler. McDonnell & Miller model
FS74W Vapor-proof SPDT, NEMA 4X switch (300
PSIG (21 bar) DWP), -20°F to 300°F (-29°C to 149°C),
with 1¼ inch MPT connection for upright mounting in
horizontal pipe (Field-Mounted).
DIFFERENTIAL PRESSURE SWITCH – Alterna-
tive to an above mentioned flow switch. Pretempco
model DPS300AP40PF-82582-5 (300 psi max. working
pressure), SPDT 5 amp 125/250VAC switch, Range
0 - 40 PSID, deadband 0.5 - 0.8 psi, with 1/4” NPTE
Pressure Connections.
REMOTE DX COOLER – Asplit system arrangement
with the cooler, leaving & return water sensors, liquid
line solenoid valves, filter driers, sightglasses & TXVs
shipped loose for field connection to the air-cooled con-
densing section. The DX cooler and outdoor section will
have a nitrogen holding charge. Interconnecting rigid
piping, wiring and refrigerant are by others. Includes
YORK Service startup. See Form 150.62-NM1.1 (200)
for other application information (this option includes
the Crankcase Heater option) (Field-Mounted).
CONDENSER AND CABINET OPTIONS
Condenser coil protection against corrosive environ-
ments is available by choosing any of the following
options. For additional application recommendations,
refer to FORM 150.12-ES1 (Factory-Mounted).
PRE-COATED FIN CONDENSER COILS – The
unit's coils are constructed with black epoxy coated
aluminum fins. This can provide corrosion resistance
comparable to copper-fin coils in typical seashore loca-
tions. Either these or the post-coated coils (below) are
recommended for units being installed at the seashore
or where salt spray may hit the unit.
POST-COATED DIPPED CONDENSER COILS
–The unit's coils are constructed with dipped-cured
condenser coils. This is another choice for seashore and
other corrosive applications (with the exception of strong
alkalis, oxidizers and wet bromine, chlorine and fluorine
in concentrations greater than 100 ppm).
COPPER FIN CONDENSER COILS – The unit's
coils are constructed with copper fins. (This is not rec-
ommended for units in areas where they may be exposed
to acid rain).
ENCLOSURE PANELS (UNIT) – Tamperproof
Enclosure Panels prevent unauthorized access to units.
Enclosure Panels can provide an aesthetically pleas-
ing alternative to expensive fencing. Additionally, for
proper head pressure control, YORK recommends the
use of :
LOUVERED PANELS (Full Unit) – Louvered panels
surround the front, back, and sides of the unit. They
prevent unauthorized access and visually screen unit
components. Unrestricted air flow is permitted through
generously sized louvered openings. This option is ap-
plicable for any outdoor design ambient temperature up
to 115°F (46°C) (Factory-Mounted).